Molded pulp coated charcoal and charcoal briquettes



Aug.\9\', 1960 w.iv. DYLE v2,948,594

, MOLDED PULP COATED cHARco/u. AND i CHA AL B UETTEs .F11 Aug'. ,1956sv ZZ0\` z g4 2a* 42.2' 24 6 l M523. (JFFL-o-CKS ATTORNEY United States O Y 2,943,594 f f MOLDED PULP COATED c'HARcoAL AND cnAnoAL nmounnns william v. Doy'l'egcliesterton, 1nd., asstgnart Diamanti .National Corpontiomecorporationof Delaware I f Filed Aug. 6, 1956, Ser. j No,}602,380

z5 cnam. (CD44-6) This invention relates to fue'lfbriquettes, and more \particularly to self-starting or selbkindling charcoal and charcoal briquettes for usein building fires in open lireplaces, or in 'barbequebraziera broilers andv grilles em- PlOYed in linfiorr'nal indoor rand outdoor cooking.v

The Ordinary harcoalf charcoal which Q thec'ommereial market effort to solve thisl problem, lsmall luantities of briquettesl have been packaged'in paper bags designed to be thrown as a unit into a stove' without 'breaking open the package, but this hasrequired the use of a fixed quantity of fuel,

Patented Aug. 9, 196

Fig. 4 is a median sectional view of an individl piece of charcoal in the form of a briquette forming third embodiment of the invention;

Fig. 5 is a sectional view of an individual piece of ch: coal in the form ofa briquette forming a fourth embo ment of the invention;

`Fig. 6 is a median sectional view ofanother form individual piece of charcoal inthe form of a brique constituting a iiftli embodiment of the invention;

' Fig. 7 is a perspective view of a simple mesh bagfill with briquettes embodying the invention, showing afo1 of package suitable for storing or merchandising b quettes;

Fig. 8 is a perspective view of a unitary elongat strip of molded pulp having embedded therein a `p rality` of lumpsof charcoal, which upon separation fol individual briquettes "embodying the invention;

Fig. 9 isv a perspective view of a sheet of molded pi having embedded therein a plurality of lumps of ch; coal, which "uponseverance form individual briquetl embodying the invention;

Fig. 10 is a perspective vi'ew of an elongated she corresponding to the sheet shown in Fig. 9, rolled intc spiral form suitable for merchandising briquettes;

-Fig. 11 is a schematic view of one type of apparat suitable for manufacturing'briquettes in strip or shi form, as shown in Figs.7 and 8; and

which sometimes may betoo large or too small.` Iiurtlierl more, ordinary charcoal .briquells 'areA not selfkindlng, and a considerable quantity of amore v,readilycombustible material, such as kindling wood, must 'first be employed to ignite them.

j An'object of this invention is to provide a newand irri* proved fuel briquette which vis ``ftelfr-star=ting, being capable of becoming entirely ignited from' the directfapplication of a single burning match or taper.l f

Another object of the invention is to provide a new andimproved charcoal briquette possessing such cleanliness that it can be handled without soiling hands or clothing during'preparatio'ns for building a tire.`

Still another'object of theinvention is -to provide anew and .improv edeharcoal briquette capable of vbeing packaged and merchandised in variousforms in simple inexpensive containers?.

Yet another object 'of the invention is to provide a new andimproved'charcoalbriquette having an attraetive surface appearance and coloration designedv to enhance its sales appealand-facilitatethe identification of manufacturersbrands. t f V 'ln general, theforegoing objects are accomplished by forming a briquette comprising-alump of charcoal or compressed pulver-ized charcoalenveloped by an adherent coating offelted ibrous` pulp.v The coating may be molded onto the charcoal lumps' in a variety of configurations, and each' briquette may be provided with 'a pro jecting iin of molded pulp, whichfunctions-as a fuse and a spacerv when groups of brquet'tesare piled together heterogeneouslyin building are.

Other objects and the nature and advantages of the in@ stant' invention-will be `apparentfr'om the following description taken' in conjunction with the accompanying drawings, wherein: j i u Fig; l is la perspective'view of one formvofl an individual charcoal briquett'e embodying :the invention;

Fig. 2 isv a vertical 2'-2ofFig. 1; y Fig. 3 is a sectional` lview of an individuall charcoal Fig. 12 is a schematic view of one type of apparat suitable for manufacturing individual briquettes of t types illustrated in Figs. 1-6, inclusive.

vOrdinary charcoal-briquettes may be manufactur 'merely' by' compressing .smallI quantities of pulveriz charcoal to form molded lumps' having anydesired co figuration. A small quantity of a suitable binding agen such as al combustible resin,'may be admixed with tl powdered charcoal to endow the molded lumps wi some degree of structural strength. The Vresulta molded lumps ordinarily retain their shape' witho crumbling, unless they are subjected to'relatively seve blows; YNevertheless, the molded lumps are vvstill sui ciently friable for some particles of charcoal'- to l readily rubbed off the surfaces of the lumps, and son excess loose powdered charcoal is usually present.

In accordance with Ithe present invention`,each int vidual lump of charcoal or compressed pulverized cha coal is completely enveloped by an adherent coating i felted fibrous pulp. The' pulp coating need not be ve thick, provided it is suiiiciently thickto protect the su face of the charcoal lump. However, in lsome cases may vbe considered desirable toemploy a thick coatii of pulp, and in such cases the pulp coating-itself m: be molded in various configurations. The'pulp coatir keeps the lump briquette clean, while the pulp itself fun tions as a readily lgnitable vfuse, which renders the cor positeA briquette self-starting or self-kindling, making unnecessaryv to employ any `auxiliary kindling materi for starting a fire. In Figs. l and 2, there-is shown a charcoal briquet indicated generally-by the numeral 20, which represen the preferred embodiment of the invention. The b1 quette 20 comprises a corefZZ composed essentially '1 lcompressed pulverized charcoal, `'and a coating 24' con posed of felted pulp fibers yformed thereon. The coatir 24 may be molded on thecore 22 by methods involvit dipping, spraying, or any other vsuitable' means for di positing -,felted iibers. The core 22.4 is approximate] elliptical in yvertical cross-section. The coating 24j sectional view taken'along the line approximatelyv uniform `inl thickness, it conforms ger erally to the configuration of the core 22, and it'con pletelycove'rs the core Z2. f Formedintegrally with th coating 24 is a projecting iin 26 composed of molde ln'iquette forminga second the invention; pulp libere, shown located at the vertical midpoint c composite briquette. The fin 26 may extend ciriferentially entirely around'the briquette, or it may :nd only partially around it. This fin advantageously ctions as a fuse and a spacer when groups of [uettes are piled together haphazardly in building a As a spacer, the fin 26 allows ,drafts of airto ply needed additional oxygen in the-interior of a pile mquettes. In this manner, eachgbriquette -is rendered able' of catching lirefmore easily-and quickly. 'ig. 3 shows a briquette'30 formingv a secondzembodi- 1t of lthe invention. The briquette 30 isv provided 1 a compressed pulverizedcharcoal core 32,' whichv configuration and structure resembles `the `core 22 wn in Fig. 2 for-the preferred embodiment. The s 32 is completely covered by a relatively thick ded pulp coating 34. This coating is 'approximately are orrectangular inv crossfsectiomas shown in Fig. md it is approximately cubical in: overall shape. The esand corners of the coating '34 serve as fuses and :ers for the briquette 30, in the same way that the 26 performs on the brquette 20. n the third embodiment of the invention, shown in 4, a 'briquette 40 comprises aliirregular lumpof rcoal ycore 42, and a relatively thick molded pulp ting 44. The coating 44 completely covers and ad- :s tightly to the c'ore'42. The exterior of the coat- 44 is circular in cross'sectio'n, as shown in Fig. 4, it is spherical in overall shape. It is evident that shape results in the formation of the desired spaces veen adjacent brquettes, when a plurality of Vthem heaped in a pile in preparation for building a fire. n the embodiment shown in Fig. S, a briquette 50 iprises a charcoal core 52 which is similar in cornition and in configuration to the core 42 of Fig. 4. wever, the core 52 is completely covered by a relaly thick pulp coating 54 which is molded in form of ihe, or some other regular hexahedron. nstead of molding thick pulp coatings to form regular determined shapes, as in the embodiments shown in s. 3,4 and 5, it may be considered satisfactory-to n thin pulp coatings conforming to any irregularly ped core, as shownv in Fig. 6. In this embodiment, a [uette 60 includes an irregular charcoal core ,62 corrending in composition and configuration to the cores and 52 of Figs. 4 and 5, respectively. The core 62 mmpletely covered by a relatively thin -pulp coating conforming to the irregular shape of the core 62. )ue to the cleanliness made possible by their pulp tings, the briquettes shown in Figs. l to 6, inclusive, y be conveniently handled, stored and merchandised vidually in any desired number, in the same manner )ranges o'r any other small unitary commodity. They y be handled and stored loosely, or they may be kaged in any suitable simple inexpensive container. an example, Fig. 7 shows a plurality of briquettes 70 iodying the invention, enclosed within a simple large :h bag 72 of the type commonly employed to `store nges. In this type of container, the briquette's are trly visible, whichfact may increase the sales appeal he product. lrquettes embodying the invention may be packaged merchandised Iin other convenient ways. Fig. 8 ws a unitary elongated strip 80 composed of felted a, in which a plurality of lumps 82 of compressed rerized charcoal are embedded at intervals throughthe length of the strip. Such strips may be sold by yard. Any desired number of individual briquettes aodying the invention may be obtained by severing strip 80 into units each containing one of. the lumps The strip 80 may have an indefinite length, and it l be molded continuously while simultaneously emding the lumps 82 therein, in a manner to be debed hereinafter in connection with' a description of apparatus shown in Fig. ll.

rig. 9 shows a" sheet 90 composed of qfelted molded pulp in which a plurality of lumps 92 of compressed pulverized charcoal are embedded in uniformly spaced columns and rows. ln other respects, the sheet 90 is similar to the strip shown in Fig. 8. The strip 90 can be readily cut into units each containing one of the lumps 92., thereby forming individual briquettes embodying the invention. In area, the sheet may have any convenient size, tolenable stacks'A of such sheets to be arranged on shelves for'storage or sale. If desired,

longer sheets, otherwise corresponding to the sheet 90, i

may be rolled into'a spiral form for vconvenient storage. For example, Fig. 10 shows a spirally rolled sheet 94, similar to the sheet 90, secured in its spiral form by a string 96. In this form, 'sheets of briquettes may be sold by the bundle or'hy sections thereof.

In the manufacture of strips and sheets having embedded lumps of charcoal, such as the strip 80 and the sheet 90 shown in Figs. 8 and 9, respectively, apparatus of the type shown schematically in Fig. l1 may be employed. This apparatus includes a pair ofrolls over which passes previously prepared felted pulp molded in sheet forrn on opposite sides of a chute 102 which contains a stack of lumps 104 composed of compressed pulverized charcoal. Over the rolls 100 a pair of pulp webs 106 are drawn continuously and fed into the bite between a pairof cooperating compression roller's 108 mounted beneath the chute 102. The lumps 104 are dispensed in predetermined order by mechanism not shown from the chute 102 into the bite between the sheets 106, resulting in the formation of a composite laminated strip 110 corresponding in structure to the strip 80 or the sheet 90. The strip 110 may be continuously wound into a spiral form on a takeup reel 112. A pair of water supply pipes 114 may be mounted above the rollers 108 for spraying water upon the sheets 106 just before they enter the bite between the rollers 108, in ordei to dampen the sheets 106 suiciently to enable the rollers 108 to mold them together in laminated form.

In Fig. l2, there is shown schematically one type of apparatus suitable for the production ofthe briquettes illustrated in Figs. 1 to 6, inclusive. This apparatus includes a plural member chute 200 from which a plu- -rality of lumps 202 of compressed pulverized charcoal are dispensed one at a time to a series of suction tubes 204 projecting radially from the periphery of a rotatable carrier 206. The tubes 204, which extend between the plural members of chute 200, receive the lumps 202 from the chute 200 and advance them successively through an open tank 208 containing liquid pulp slurry, which may be a suspension of `pulp fibers in water. Due to the fact that the lumps 202 of compressed charcoal are porous, the suction applied by the tubes 204 causes pulp bers tol be extracted from the slurry in the tank 208, and deposits the fibers in layers coating the exterior surfaces of the lumps 202. Excess water is sucked through the interiors of the lumps 202, thence inwardly through the tubes 204, to a central hollow shaft 210 on which the carrier 206 is rotatably mounted.

As the result of being dipped into the pulp slurry contained in the tank 208, the charcoalA lumps 202 are cornpletely coated with a layer of wet pulp fibers, except for the small circular areas where the lumps were engaged by the suction tubes 204. These small uncoated areas may be covered by spreading the surrounding layers of wet pulp by means of a blowing or a rubbing action. This may be accomplished by transferring the coated lumps 202 successively from the tubes 204 to a series of 202, the male -die 216 spreads the wet pulp coating.

aereas the surface of each lump 202 by a blowing or a amines-t rubbing action. At the same time, the pulp coating on each lump may be molded to form a projecting fin, such as the fn 26 shown in Figs. 1 and 2. Finally, the completely coated lumps 202 areV advanced.y to a discharge chute218 leadingl to a drying device '('not shown).

While it is preferred to` spread the pulp fibers over.

the incompletely coated charcoal lumps 202 in the abovedescribed manner, in order to cover said lumps com-4 pletely with la uniform adherent coating of felted fibrous I pulp, itis apparent that'the incompletely coated charcoal lumps 202are directlyhusable for thev stated-purr' poses of the invention. Thus,'even'though asniall area of each charcoal lump 202 may' lackl a coating of the pulp fibers, it is still usable advantageously as a charcoal fuel, and this applies equally to all of the illustratedv embodiments of the invention. It is evident that the type of apparatusillustrated in Fig. 12 is capable of producing briquette's having various configurations, corresponding to any one of the embodiments of Athe invention'shown in Figs. l to 6, inclusive. The suction tubes 204 are capable of engaging and grip-l ping charcoal lumps 'having practically any regular or irregular configuration. 4Where necessary,r other types of gripping devices may be substitutedjffor the suction tubes 204. Furthermore, othertypes voffdipping apparatus may be used .in place of the rotatable carrier 206.

Thick coatings ofpulp may .bejdepositedv' on thefcharcoal lumps in the tank 208, and the cooperating 'dies 212 and 216 may be suitably formed to mold the Pulp into the spherical `and cubical shapesjshowninFigs. 3, 4

The materials employed in the manufacture of briquettes employing the invention are rordinary pulverized -charcoalor lumps of charcoal and ordinary wood pulp fibers. A small amount of a resinous binding agent may be incorporated into the charcoal. Any yreadily combustible cheap grade of pulp is suitable. -If desred,'various -dyes may be -incorporated into the pulp toproduce briquettes having any desired color. Bright colors might add to the attractiveness of the vbric'luettes, therebyincreasing sales and identifying manufacturers brands.

The principles of the vinvention have been illustrated and described in several'diiierent embodiments. However, it is evident that briqucttes embodying the invention may be made 'in many other shapesand forms, and that other apparatus and methods may be employed for their manufacture. l' 1 l l l It will be obvious to those skilled in the art that various vchanges may be made without departingfrom 'the spirit .ing circumferentially around the coatingon the exterior of the lump. y v l 2. A charcoal fuel comprising a lump of,ch arcoal enveloped by anv adherent self-kindling coating-of felted fibrous pulp. y. v.

3. A charcoal fuel comprising a ybriquette4 of4 compressed pulverized charcoal, and an adherentv self-kindling layer of felted fibrous pulp molded around and substan tially completely covering said briquette. 4. Av charcoal fuel comprising a 4briqtnttte of compressed pulverized charcoal, an adherent coatinggof felted fibrous pulp molded around and completely covering the briquette, and a projecting fin of molded fibrous pulp herent coating of felted fibrous pulp completely covering the briquette in conformity with the shape Aof the briquette, and a projecting fin of molded fibrous pulp formed'integrally with and extending circumferentially around the coating on the exterior of the briquette.

6. lA charcoal fuel comprising a lump of charcoal, and a relatively thick adherent coating of felted fibrousr pulp completely covering the lump and molded into anapproximatelyl cubical configuration.

7. A charcoal fuel comprising a briquette of 'compressed pulverized charcoal having a shape approximately elliptical in vertical cross-section, and a relatively thick adherent ,coating of felted fibrous pulp completely covering the lump "molded into an approximately cubical conguration.

8. A charcoal fuel comprising an irregularly shaped lump of charcoal, and a relatively thick adherent coating of felted fibrous pulp completely covering the lump and molded into a regular geometrical configuration.

9. A packaged charcoal fuel for braziers and the like, comprising any elongated strip of indefinite length molded from felted fibrous pulp, and a plurality of lumps-of charcoal embedded in the strip at intervals along its length. v l- 10. A packaged charcoal fuel for braziers and the like, comprising an elongated strip of indefinite length molded from felted `fibrous pulp, and a plurality of briquettes of compressed pulverized charcoal embedded in the strip at intervals along its length.

l1. A method of making charcoal fuel,'comprising the steps of molding a layer of felted fibrous pulp completely around a lump of charcoal, and molding a prodeposited'pulp across the surface of the lump to cover it completely.

' 14. A method of making pulp coated charcoal briquettes, comprising the steps of successively dipping a plurality of lumpsv of compressed pulverized charcoal into liquid pulp slurry, applying suction to a portion of the surface of each lump to deposit a layer of wet fibrous pulp on the surface of the lump, successively advancing the coated lumps to a pair of cooperating compression di, and compressing the lumps between the dies thereby spreading the deposited pulp across the surfaces of the lumps to cover them completely and form an integral y molding the sheets around the lumps to embed them formed integrally with and extending circumferentially around the coating on'th'e exterior of .the briquette.

5. A charcoal fuel comprising a briquette of compressed pulverized charcoal having afshape' approximately elliptical in vertical cross-section, vitjrelntively adtherein. l

16. A charcoal fuel comprising an irregularly shaped lump of charcoal, and an adherent coating of felted fibrous pulp molded around and completely covering the lump of charcoal, said coating conforming approximately to the shape of the lump of charcoal and being approximately unifomi in thickness over its entire area.

' 17. The charcoal fuel defined by claim 8, wherein the felted fibrous pulp coating is molded into a generally -spherical configuration.

herent covering over. substantially allof. the surface :a of each. of said-lumps.

Z0; `A packaged charcoalfuel for'b'raziers and the like, nprising a plurality of briquettesof rcompressed `pulized charcoal admixed'with a resinousbinding agent d molded into a predetermined shape, sadbriquettes `ng spaced ina plurality of adjacent rows'v and columns, :l a sheet of felled brouspulp molded around and lming an adherent covering' 'over substantially all of surface area of each of said briquttes.

Z1. A charcoal fuel vcomprising a lutnp 'of charcoal,

i an adherent layerQof felt'ed brous'pulp molded undand covering substantially all ,except asmall Aarea i thesurface of said lump.'

Z2. The charcoal fuel defined by clam"21,rvvherein the v np of charcoal is a briquette of compressedpulverikzed ircoal admixed with a'resinous'binding agent.

23. A packaged charcoal fuel fory braziers and thenlike, i

nprising a plurality of lumps. of charcoal spaced ina irality of yadjacentrows and columns,l and a pair' of :ets of felted fibrous pulp vmolded onto opposite sides said lumps to embed them kbetween` the sheets, said :ets being united to each other and beingfmolded und each 'of said lumps toform an v adltierent cover# 1 oversubstantially all ofl the surfaces thereof.' 'p

. 8 24. The packaged charcoal fuel dened by claim 23,

wherein each lump of charcoal is a bn'quette of com- Refer-ences cited in the me of this paient UNITED STATES PATENTS 747,282 Wallgren Dec. l5, 1903 1,481,866 Heist Jan. 29, 1924 2,012,405 Sallsberg Aug. 27, 1935 2,094,661 Macleay et al. Oct. 5, '1937 2,240,335 Keil Apr. 29, 1941 2,242,372 Schneider May 20, 1941 2,257,573 Randall Sep't.'30, 1941 2,666,695 Brody Jan. 19, 1954 2,760,412 Lemieux Aug. 28, 1956 2,799,563 Shenker` July 16, 1957 2,822,251 Swinehart et al. Feb. 4, 1958 *l FOREIGN PATENTS 13,637 Great Britain Aug. 26, 1887 85,358 Switzerland June 1, 1920 

1. A CHARCOAL FUEL COMPRISING A LUMP OF CHARCOAL, AN ADHERENT COATING OF FELTED FIBROUS PULP MOLDED AROUND AND COMPLETELY COVERING THE LUMP, AND A PROJECTING FIN OF MOLDED FIBROUS PULP FORMED INTEGRALLY WITH AND EXTENDING CIRCUMFERENTIALLY AROUND THE COATING ON THE EXTEIROR OF THE LUMP. 